1996 DS chaging issue

[pmangr]

I have a friend that has a 1996 DS Electric Cart. The first part of the Serial number is A9633. Anyway, like many here who have the issue where they plug their charger in and hear a click and nothing else, I want to have the instructions to bypass the OBC to test the charging circuit.

I've embedded a photo to help clarify things. The yellow circle that has the arrows pointing to it, is that fuse right in back of the charging port. If I am going to put a jumper wire, do I first disconnect a lead and then put a jumper? Also which lead am I disconnecting? I know to jump it to the #6 Battery Neg terminal. But, I'm just not certain of the other end.

[Stevegrmich]

. . . the quick way to test obc charge circuit is to do the bypass in the charger as shown in below pic . . . pay attention to all warnings . . .

[Stevegrmich]

. . . the yellow "thingy" in your pic is the sense lead fuse . . .


. . . on a side note . . . we need a Tahoe or ScottyB to write up a STICKY for OBC bypass procedure . . . this subject comes up time and time again in threads . . .

[pmangr]

Originally Posted by Stevegrmich

. . . the yellow "thingy" in your pic is the sense lead fuse . . .


. . . on a side note . . . we need a Tahoe or ScottyB to write up a STICKY for OBC bypass procedure . . . this subject comes up time and time again in threads . . .

I agree, that is why I included a photo. I was hoping to see responses with photos as well. Feel free to use my photo for a sticky if it helps.

[pmangr]

So if I bypass this in the charger, it's the same as bypassing the OBC of the cart? In other words, if the charger hums and the meter goes up where it's supposed to, that would indicate that the OBC in the cart is bad?

Originally Posted by Stevegrmich

. . . the quick way to test obc charge circuit is to do the bypass in the charger as shown in below pic . . . pay attention to all warnings . . .

[Stevegrmich]

Originally Posted by pmangr

So if I bypass this in the charger, it's the same as bypassing the OBC of the cart? In other words, if the charger hums and the meter goes up where it's supposed to, that would indicate that the OBC in the cart is bad?

. . . doing the OBC bypass in the charger would show there is either a problem with the charger or the charge circuit in the cart . . .

[pmangr]

Originally Posted by Stevegrmich

. . . doing the OBC bypass in the charger would show there is either a problem with the charger or the charge circuit in the cart . . .

According to my friend, he's already taken the charger in for a diagnosis and it's fine. I did a cursory check of things last night and without taking somethings apart, didn't see anything wrong. I did a continuity check across the fuse with the cover, shown in the photo, but not the yellow one. He said that his son had checked it, but I'll double check it as well before doing the jumping.

[Stevegrmich]

Originally Posted by pmangr

According to my friend, he's already taken the charger in for a diagnosis and it's fine. I did a cursory check of things last night and without taking somethings apart, didn't see anything wrong. I did a continuity check across the fuse with the cover, shown in the photo, but not the yellow one. He said that his son had checked it, but I'll double check it as well before doing the jumping.

. . . quick test for charger is to plug it into another cart . . . however, if no other cart is available, the bypass in charger will point to either a charger issue or an OBC/cart circuit issue . . .

[pmangr]

UPDATE:

My friend has a friend with the same model cart. So they hooked up his charger to test it and it seems to work perfectly. Friend #2's charger exhibits the same issue when hooked up to Friend #1's cart. Friend #1's charger works fine on Friend #2's cart.

At this point, I believe it is safe to say it is NOT the charger.

It appears, however, that the cart is getting some kind of "trickle" charge as he is able to use the cart still as long as he lets it charge 24 hours or so.

If this is the controller, where would a good place be to purchase a new one? And which one should he purchase?

Thanks....